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United States Patent |
5,658,647
|
Magill
,   et al.
|
August 19, 1997
|
Garment labeling system, equipment and method and elastomeric label for
use therewith
Abstract
A demand actuated system for automatically feeding, printing, cutting and
applying a garment label composed of a strip of two layer laminated
thermoplastic, elastomeric, preferably, polyurethane, film includes a
printer and a bonder arranged for conjoint operation. The printer prints
computer controlled images, by means of a thermal ink transfer ribbon,
directly onto a layer of higher melting point resin and the bonder fusion
bonds the other layer, of lower melting point resin, to the garment piece
substantially without distortion of the imprinted image. A special two
layer thermoplastic elastomeric label film is provided for use in the
system.
Inventors:
|
Magill; Raymond H. (Warminster, PA);
Sellers, Jr.; George T. (Philadelphia, PA);
Grapentine; Ralph W. (Paramus, NJ);
Brown; Wonnie (Haledon, NJ)
|
Assignee:
|
Avery Dennison Corporation (Pasadena, CA);
Electro-Seal Corp. (Pompton Lakes, NJ)
|
Appl. No.:
|
482635 |
Filed:
|
June 7, 1995 |
Current U.S. Class: |
428/195.1; 428/411.1; 428/423.1; 428/423.3; 428/913 |
Intern'l Class: |
B32B 003/00 |
Field of Search: |
428/79,349,355,411.1,913,914,195,423.1,423.3
156/209,230
|
References Cited
U.S. Patent Documents
2602560 | Jul., 1952 | Pargh | 216/55.
|
3114667 | Dec., 1963 | Braun et al. | 156/384.
|
3119728 | Jan., 1964 | Janapol et al. | 156/583.
|
3129130 | Apr., 1964 | Lerner et al. | 156/367.
|
3589966 | Jun., 1971 | Gardner et al. | 156/277.
|
3616086 | Oct., 1971 | Nooder | 156/518.
|
3816211 | Jun., 1974 | Haigh | 156/309.
|
4069727 | Jan., 1978 | Sparks et al. | 83/16.
|
4078113 | Mar., 1978 | Starbuck et al. | 428/196.
|
4194618 | Mar., 1980 | Malloy | 206/205.
|
4256795 | Mar., 1981 | Day et al. | 428/196.
|
4269885 | May., 1981 | Mahn | 428/216.
|
4390387 | Jun., 1983 | Mahn | 428/90.
|
4405401 | Sep., 1983 | Stahl | 156/248.
|
4423106 | Dec., 1983 | Mahn | 428/207.
|
4439257 | Mar., 1984 | Sato et al. | 156/64.
|
4610904 | Sep., 1986 | Mahn, Sr. et al. | 428/79.
|
4981742 | Jan., 1991 | Haigh | 428/64.
|
5040461 | Aug., 1991 | Van-Ocker | 101/288.
|
5111216 | May., 1992 | Richardson | 346/76.
|
5230765 | Jul., 1993 | Weiselfish | 156/350.
|
5364688 | Nov., 1994 | Mahn, Jr. | 428/187.
|
5411783 | May., 1995 | Mahn, Jr. | 428/79.
|
5413841 | May., 1995 | Mahn, Sr. et al. | 428/195.
|
Other References
Water Resistant tape shown at 1992 Bobbin Apparel Trade Show held in
Atlanta, Georgia.
1978 Product Bulletin "Print'n Seal Electro-Sealer.RTM.", Model 7112 RP,
labeled Exhibit A.
"New Products" article, Apparel Manufacturer, Apr. 1990 Authored by
W.G.Kluge and P.C.Sabio, entitled Underwear Labeling Systems, labeled
Exhibit B.
|
Primary Examiner: Krynski; William
Attorney, Agent or Firm: Synnestvedt & Lechner
Claims
What is claimed is:
1. A bar-code-readable, garment label bearing a variably imprintable
electronically generated imprinted image, said label being soft and
pliable and being capable of withstanding repeated commercial and home
laundering and consisting essentially of two layers of thermoplastic
polyurethane, a first layer and a second layer, in face to face surface
contact with each other and the second said layer being fusion bonded to
the fabric of a garment piece while the label remains bar-code-readable,
the first of said layers comprising polyurethane having a melting point
substantially higher than that of the second of said layers, the second of
said layers of the label being fusion bonded by heat and pressure to the
garment piece with the said second of said layers facing the fabric of the
garment piece, and the first of said layers bearing said imprinted image
transferred thereonto, under the control of a pre-programmed computerized
controller, according to a data stream applied so as to supply the
variably imprintable data necessary to print labels for garments of
various sizes, colors, styles, material content, washing and cleaning
recommendations, and other indicia, from a thermal ink transfer medium by
the application of heat and pressure prior to the bonding of said second
layer to the garment piece, both of said layers remaining soft and pliable
after said bonding.
2. A label according to claim 1 in which said first layer of relatively
high melting point polyurethane consists of a layer of polyurethane having
a melting point in the range of from about 355.degree. F. to about
365.degree. F., and in which said second layer of relatively low melting
point polyurethane consists of a layer of polyurethane having a melting
point in the range of from about 275.degree. F. to about 290.degree. F.
3. A label according to claim 2 in which said first layer of relatively
high melting point polyurethane is about 0.002 inches thick and said
second layer of relatively low melting point polyurethane is about 0.001
inches thick.
4. A label according to claim 3 in which at least said first layer
comprises an opacity enhancing additive in sufficient amount to
substantially and materially enhance the opacity of the label.
5. A bar-code-readable, garment label bearing a variably imprintable
electronically generated imprinted image, said label being soft and
pliable and being capable of withstanding repeated commercial and home
laundering and dry cleaning and consisting essentially of two layers of
thermoplastic elastomeric synthetic resin, a first layer and a second
layer, the second layer being fusion bonded to the fabric of a garment
piece while the label remains bar-code-readable, the first of said layers
comprising resin having a melting point substantially higher than that of
the second of said layers, the first of said layers bearing said imprinted
image transferred thereonto, under the control of a pre-programmed
computerized controller, according to a data stream applied so as to
supply the variably imprintable data necessary to print labels for
garments of various sizes, colors, styles, material content, washing and
cleaning recommendations, and other indicia, from a thermal ink transfer
medium by a first application of heat and pressure for a first duration,
the second of said layers of the label being fusion bonded to the garment
piece with the said second of said layers facing the fabric of the garment
piece by a second application of heat and pressure for a second duration,
both of said layers remaining soft and pliable after said bonding.
6. A label according to claim 5 in which the first and second layers of
resin comprise polyurethane resins, and in which the second application of
heat is in the range of from about 350.degree. F. to about 500.degree. F.,
the second application of pressure is from about 50 psi to about 100 psi
and the second duration is from about 1/2 sec. to about 2 secs.
7. A label according to claim 6 in which the first application of heat and
pressure is for a duration less than that required to heat either of the
polyurethane layers above its melting point, and the second application of
heat and pressure is for a duration sufficient to heat the second of said
layers to a temperature above its melting point, but less than that
required to heat the first of said layers to a temperature at which the
imprinted image will be so distorted as to no longer be bar-code-readable.
Description
BACKGROUND OF THE INVENTION
The present invention relates to a demand actuated system, equipment and
method for automatically feeding, printing, cutting and applying garment
labels, and a novel thermoplastic elastomeric, preferably polyurethane,
label material cooperating therewith.
Prior to the invention, there has not existed in the apparel market a
bar-code readable, variably imprintable label capable of withstanding both
home laundering and commercial laundering and dry cleaning, which could be
automatically, under the control of a pre-programmed computer/controller,
fusion bonded to a garment piece. The principal means of imaging and
affixing of labels has been impact hot stamping to imprint the image
followed by sewing. Various prior art devices are identified and discussed
below.
U.S. Pat. No. 5,111,216 discloses a manually operated thermal transfer
device for transferring data from a database to a strip of adhesive-backed
tape by thermal transfer from a transfer ribbon associated with the print
head of a computer-controlled printer. The printed portion of the tape is
then manually advanced and severed, and applied to a selected substrate at
another location.
U.S. Pat. No. 3,114,667 discloses a two-station garment marking machine in
which a label is printed at a printing station and then applied to a
garment by, for example, heat sealing at a label affixing station.
U.S. Pat. No. 3,616,086 discloses an automated label apparatus including
tape feeding means, printing means, cutting means and application means,
with the tape feeding means being mounted to pivot or oscillate between a
printing station shown in FIG. 2 and a cutting and application station
shown in FIG. 1.
U.S. Pat. No. 3,199,728 discloses a label pressing machine for applying a
label comprising a facing having an underlying film of bonding material
adapted to adhere to a fabric under heat and pressure.
U.S. Pat. No. 3,816,211 discloses a method of making an embroidered emblem
involving bonding by the use of polyurethanes.
U.S. Pat. No. 3,589,966 discloses a method of permanently identifying
textile fabrics by marking with a dye resistant ink onto a tape and then
bonding a tape segment onto the garment. The tape may be prepared from a
variety of materials, including polyurethanes.
U.S. Pat. No. 2,602,560 discloses apparatus for automatically removing a
thermoplastic type of label from a label storage magazine, positioning it
accurately centered on a designated portion of an article and affixing it
thereto by the application of heat and pressure.
U.S. Pat. No. 3,129,130 discloses means for automatically removing labels
from a supply thereof, applying the labels to garments and securing them
by high frequency heating.
U.S. Pat. No. 4,439,257 discloses a printer for printing labels which are
temporarily adhered in series to a web of backing paper. A label holder is
removably attached to the printer for receiving and rolling up the printed
composite label web. There is a label applier separate from the printer,
which unrolls the composite web from the label holder and delaminates the
labels from the backing paper web and then applies the delaminated labels
to garments.
U.S. Pat. No. 5,230,765 discloses an automated labeling apparatus which can
apply identifying labels directly onto a sheet of cloth prior to cutting
the cloth into garment pieces.
Whatever the apparent merits or demerits of various prior art equipment
respecting the performance of the basic function of applying variably
printable labels to garments, presently the apparel industry is not using
any of the prior art techniques for the applying, by heat sealing, and the
like, of labels to garments, except, possibly, in relatively isolated
instances. The apparel industry is, by and large, sewing labels into
garments.
In the printing of labels according to certain of the prior art techniques,
labels are conventionally presented to the print head in the form of
spaced die-cut label stock adhesively attached to a carrier web. The web
is fed at a controlled rate across the print head by means of a motor
driven roller which serves to pinch the web of labels and a transfer foil
against the print head with the print line being tangentially aligned with
the roller. The label web is advanced by friction between the roller and
the back surface of the web to provide a positive controlled drive of the
web. The transfer foil, which travels with the web, acts as a sliding
bearing surface against the smooth contact face of the print head.
Dispensing of the printed label from the web is accomplished by sharply
changing the direction of travel of the web by passing the web over a
sharp edge known as a peeler bar. Upon leaving the web, the label is
conventionally transferred by air jet to an applicator head on which it is
held by vacuum. The applicator head is then moved into engagement with the
product to be labelled which typically is passing thereby on a conveyor.
Pressure sensitive adhesive is frequently used in prior art labelling,
particularly with respect to the labelling of paper, or cardboard boxes,
or other containers having a surface to which typical pressure sensitive
adhesives successfully adhere. However, the use of pressure sensitive
adhesives does not produce satisfactory results in connection with the
labelling of garment pieces, because the pressure sensitive adhesives do
not adhere sufficiently strongly to the garment pieces in order to perform
the intended function of the labelling associated with garments. Such
labelling must be capable of successfully withstanding repeated home or
commercial laundering or dry cleaning. It is because of such factors that
the apparel industry today is still approaching the labelling of garment
pieces by, essentially, preparing separate or separable labels, which are
accumulated for storage, and then retrieved, usually at another location,
and sewn into the garment pieces.
SUMMARY OF THE INVENTION
The invention provides a system, equipment and method, together with a
special film of thermoplastic elastomeric synthetic resin, preferably
polyurethane, label material, for direct application of printed images
onto the label material, followed by direct application of the label
material to the garment pieces, without the use of an intermediate web, or
tape, of backing material to support and transport labels from one place
to another, and without the accumulation and storage of printed labels.
Thus, the invention provides for direct in-line use of a printer and a
bonder, under the control of a pre-programmed computer/controller,
together with a special label material film composed of two layers of
thermoplastic, elastomeric material, preferably polyurethane, one layer
being of a higher melting point thermoplastic particularly selected and
adapted to have the label information imprinted thereon, and a second
layer of a different thermoplastic, of lower melting point, which is
particularly selected and adapted to serve the function of fusion bonding
the layer having the imprinting thereon onto the garment piece to be
labeled, substantially without distortion of the printed image.
Accordingly, it is an object of the invention to provide a system to label
garments with a permanently bonded plastic film material whose variably
printable data, preferably bar-code readable, provides the consumer care
and content information, as well as the garment manufacturers' and
vendors' process data information, the label being capable of enduring,
repeatedly, a wide variety of commercial and home laundering conditions
and processes.
It is a further object of the invention to provide a system for integrating
the operations of (a) a printer, capable of running with what is sometimes
referred to herein as "notchless" stock, meaning a continuous film of
actual label material, without interruptions or notches therein separating
or semi-separating the material into individual labels, and without the
use of any supplementary or backing web, and (b) a thermal bonder unit,
capable of applying the labels, as they are imprinted, by fusion bonding
directly to the garment pieces to be labeled, substantially without
distortion of the printed image.
Another object of the invention is the provision of a label film,
preferably in roll form, consisting of two thermoplastic layers,
preferably polyurethane, a high melting layer particularly well suited for
carrying imprinting, and a low melting layer particularly well suited to
serving as a fusion bonding agent.
The labeling system and label material of the invention can eliminate
manufacturing steps which currently typically include handling, stacking,
unstacking, and sewing of a label into a seam. It can also eliminate
independent steps of printing, bundling and shipping to remote plants for
sewing.
A substantial saving of the time required to conclude a garment labeling
step is accomplished by the invention. Currently garment labeling,
according to the prior art processes and using the prior art equipment,
typically requires from 5 to 7 seconds to complete the labeling step. By
utilization of the invention, this time can be cut to an estimated 3
seconds.
The system is responsive to two different commands from the operator.
Starting from an at rest condition, for example when the system is turned
on for a day's operation, the system is demand actuated, meaning that the
operator presses a "jog" button to initiate, under the pre-programmed
control of a computer/controller, a cycle of feeding, printing and cutting
a garment label. As the preparation of a label is performed, the operator
inserts a garment or garment piece onto a work platform comprising a
garment piece support and depresses dual (for reasons explained
hereinafter) trip switches which initiate the label application portion of
the system, which in turn initiates another label feed, print and cut
cycle of the label preparation portion of the system to ready the next
label for the next time that the operator again depresses the dual trip
switches.
The system of the invention operates with the inclusion of a thermal ink
transfer ribbon, which transfer ribbon comes in roll form, as is well
known by those skilled in this art.
An advantage of the system of the invention is the matter of operating the
label printer under the control of a computerized controller, so that a
data stream can be sent to the controller where it is stored and retrieved
and applied as needed in order to supply the variably printable data
necessary in order to print labels for garments of various sizes, colors,
styles, material content, washing and cleaning recommendations, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the invention will be more readily
understood from a consideration of the following detailed description,
taken with the accompanying drawings, in which:
FIG. 1 is a side elevational view of the system of the invention.
FIG. 2 is a plan view of the system shown in FIG. 1.
FIG. 3 is an end elevational view, of the left end of the equipment shown
in FIG. 1, this view being on a larger scale than FIGS. 1 and 2.
FIG. 4 is a fragmentary, enlarged sectional view of a garment label
according to the invention after it is positioned on a garment piece, but
before it is partially fused, the view being indicated by a dot/dash oval
appearing on FIG. 3.
FIG. 5 is a sectional end elevation taken on the line 5--5 of FIG. 1, but
on a larger scale as compared to FIG. 1, of the guillotine type cutting
mechanism of the invention.
FIG. 6 is an illustration of a typical imprinted label according to the
invention.
FIG. 7 is a fragmentary exploded view of the encoder disc and the sensor of
the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Turning to FIG. 1, the system of the invention incorporates a printer 10,
and a bonder 11, which are mounted together for conjoint operation.
The printer, mounted on a base 12, includes a housing 13 on which various
parts are mounted. A spool 14 of label film 15 is mounted for rotation on
a support arm 16 extending from the housing 13. The arrow 40 indicates the
direction of travel of the label film from the supply reel 14 into the
printing mechanism of the printer 10. The film passes over a rear film
feed roller 17 and a platen roller 18 mounted opposite to the print head
19, after which the film travels directly into a cutting station
associated with the bonder mechanism 11. The print head bell-crank lever
20 is mounted for pivotal motion between a down position shown in full
lines in FIG. 1, in which the print head contacts the label film, and an
up position, indicated by the dash lines 21 in FIG. 1, in which the print
head is out of contact with the label film.
The imprinting on a label film is accomplished by the use of thermal ink
transfer ribbon which, by the application of heat and pressure by the
print head, selectively transfers thermal ink from the thermal ink ribbon
directly to the label film. Thermal transfer printing requires the
precisely controlled feeding of the sheet being printed with respect to
the print head heater elements known as the print line. Heat and pressure
at the print line effect the transfer of resin-based ink from the ink
transfer foil to the label surface.
A supply spool 22 of thermal ink transfer ribbon 23, traveling in the
direction indicated by the arrows 24, unreels from the spool 22 which is
mounted by means of the shaft 25 onto the frame 13. The ribbon travels
between an upper ribbon deflector plate 26 and a lower ribbon deflector
plate 27 downwardly and in between the print head 19 and the platen roller
18, where it travels in surface to surface contact with the label film 15
for the purpose of permitting an intelligence to be imprinted on the label
film by the action of the print head, under appropriate heat and pressure.
The used or spent ribbon is separated from the label film as it exits from
the passage between the print head 19 and the platen roller 18, and the
spent ribbon then travels upwardly and over the ribbon feed roller 28, and
an idler roller 29 to the ribbon take-up spool 30 mounted on the ribbon
rewind shaft 31.
Web guide mechanism 34, which is adjustable by means of the web guide knob
36 and the locking knob 35 provides for precise lateral positioning of the
label film 15 after it passes under the idler roller 37 on its way into
contact with the print head 19 and the platen roller 18.
The outer support frame 38 provides for the mounting onto the framework 13
of the idler rollers 28 and 29, and print head lever 20, carrying the
print head 18 by means of print head mounting plate 39.
The film timing motor pulley 70, mounted on the shaft 71 of the timing
motor 72 (see FIG. 7) is interconnected by the timing belt 73 with the
pulleys 74 and 75, mounted respectively on the shafts of the platen roller
18 and the rear roller 17. As best seen in the exploded view of FIG. 7,
the encoder disc 76, having darkened spaced segments 77 thereon, is
mounted on the shaft 78 of the pulley 74, which is mounted for conjoint
movement with the platen roller 18.
The printed circuit board 79 is mounted by means of bracket 80 to the frame
13 of the printer. A sensor 81 having a sensor source 82 is under the
control of the printed circuit board 79, which in turn is connected by
means of the electrical connections 83 with the computerized controller
(not shown) for the unit. The light source 82 looks at the encoder disc.
The label length is input from the pre-programmed format as part of the
data stream from the computer/controller, and when the last line of the
format has been printed, the pre-programmed control logic opens to look
for a feed signal. The signal comes from the next darkened segment 77 on
the encoder disc, which is read by the sensor light 82 and transmits a
signal to stop the feed.
Directing attention to FIG. 6, the label 90 of the invention includes a
number of different kinds of information, including a bar-code-readable
section 84. The phrase "bar-code-readable" has special significance and
meaning in the context of this specification. The use of bar codes on
products is rapidly becoming more and more widespread. The bar codes are
"read" by a pick-up device, associated with a computer, for multiple
purposes, including inventory control, and customer check-out. The bar
code must be imprinted with a special degree of precision in order to be
quickly and accurately read by the reading device and, further, the
printed image must not be significantly distorted during the processing of
the label as it is applied to the garment piece. Thus, "bar-code-readable"
as used herein means that the bar code has the requisite precision, even
after processing according to the system of the invention including the
fusion bonding step, to enable the bar code to be quickly and accurately
read.
As seen in FIG. 4, the garment piece 57 is placed on the lower platen 56
(see FIG. 3). The label 90 consists of an upper layer 85 of relatively
high melting point polyurethane, and a lower layer 86 of relatively low
melting point polyurethane, the illustration of FIG. 4 being prior to the
application of heat and pressure to fusion bond the label to the garment
piece.
By "variably imprintable" is meant that the various different items of
information on a given label can be selected to properly identify the
size, style, color, etc., of the particular garment to which the label is
to be applied.
An opacity enhancing additive, such as a white pigment in powder form, is
preferably added to the high melting polyurethane layer in an amount
sufficient to substantially and materially enhance the opacity of the
label. For example, by increasing the whiteness of the background, the
contrast between the background and black ink printing is increased,
making the label clearer and more easily read.
The label film 15, following passage beneath the print head to receive the
printed indicia thereon, emerges from the printer 10 and passes into the
bonder 11.
The bonder 11 includes a bonder frame 41 on which is mounted a film
transport and cutting unit 42 including a pair of nip rolls 43 and 44
between which the film 15 passes. The nip rolls are driven by a stepper
motor 66 coupled to the printer cycling circuit. The film passes from the
nip rolls over a cutter block 45 and is cut into discrete labels 90 (FIGS.
3 and 7) by a guillotine type cutter assembly 46 (FIGS. 1 and 5). As shown
in the enlarged view of FIG. 5, the cutter assembly includes a knife 47,
the sharpened lower edge 48 of which is angled so as to produce a
progressive shearing of the film 15 as the knife moves vertically
downwardly adjacent the vertical face 49 of the cutting block 45. A pair
of solenoid type actuators 50 mounted on arm 51 support the blade 47 and
selectively move the blade through its cutting cycle in response to
appropriately timed electrical signals.
The severed labels 90 produced by the cutter assembly are advanced by a
conveyor mechanism 52 which includes a drive roll 53 driven by a stepper
motor 53g (FIG. 2) and horizontally spaced idler roll 54 (FIG. 1). A
plurality of O-rings 55 are stretched between the rolls 53 and 54 to
receive and advance the cut labels 90 to a position on the conveyor
mechanism from which they can be transferred selectively to a bonding
station for application to the items to be labeled.
As shown most clearly in FIG. 3, the bonder 11 includes a lower platen 56
which is electrically heated to a desired controllable temperature. The
fabric piece or item 57 to be labeled is positioned on the lower platen 56
and a label 90 is transferred from the conveyor 52 to the position shown
in FIG. 3 by a transfer mechanism to be presently described. An
electrically heated upper platen 58 is selectively reciprocatable in a
vertical direction, being supported for this function by the support
mechanism 59 which includes a pneumatic cylinder (not shown) at its upper
end. The upper platen 58 is actuatable to move downwardly to clamp the
label 90 and fabric item 57 between the upper and lower platens by the
actuation of a pair of spaced control switches 60, in this instance,
push-type switches, which, through appropriate electrical and pneumatic
circuitry, trigger the cycling of the cylinder controlling the movement of
the upper platen 58. Spaced switches 60 are employed for actuating each
cycle to insure that the operator's hands are both elsewhere when the
upper platen descends.
Since, as previously indicated, the bonding process is dependent on several
variables, namely the temperature of the upper and lower platens, the
pressure applied during the bonding period, and the time of the bonding
pressure application, each of these variables is adjustable and can be
controlled and monitored by means of the switches and instruments shown on
the bonder control panel 61 (FIG. 1). Monitoring instruments on the panel,
although not specifically shown, would typically include temperature
gauges for both the upper and lower platens, as well as a pressure gauge
to indicate the air pressure being delivered to the pneumatic cylinder.
When the label film is composed of the preferred polyurethanes, as
disclosed herein, the temperature of the upper platen is from about
350.degree. F. to about 450.degree. F., with a preferred temperature being
about 400.degree. F. and the temperature of the lower platen is from about
400.degree. F. to about 500.degree. F., with a preferred temperature being
about 450.degree. F.
The pressure applied by the platens is from about 11 psi, corresponding to
a line pressure in a pneumatic line of 13/4" diameter of about 50 lbs., to
about 28 psi, corresponding to a line pressure of about 120 lbs., with a
preferred pressure applied by the platens being about 18 psi,
corresponding to a line pressure of about 80 lbs.
A transfer mechanism 62 is provided for transferring labels from the
conveyor mechanism 52 to the lower platen 56. The transfer mechanism 62
includes a transfer arm 63 having a vacuum head 64 which is perforated and
connected through a suitable conduit (not shown) to a vacuum source. The
transfer arm 62 is supported for horizontal rotation through an arc of
90.degree. on a vertical rotatable support member 65, the rotation of
which is selectively controlled by a mechanism not shown. The vacuum head
64 is preferably formed from a hard plastic material to minimize the
formation of static electrical charges.
Means are provided for interrupting the vacuum drawn through the vacuum
head 64. With the vacuum off, the transfer arm is positioned as shown in
FIG. 1 over the discharge end of the conveyor mechanism 52. When a label
has advanced on the conveyor to a position beneath the vacuum head 64, the
vacuum is switched on, and the label is drawn upwardly and held on the
lower surface of the vacuum head. When the operator has the item to be
labeled in the proper position on the lower platen 56 as shown in FIG. 3,
the control switches 60 are both actuated to cycle the bonding cycle,
which begins with the transfer arm 63 rotating to a position wherein the
vacuum head 64 is above the lower platen 56, at which time the vacuum is
interrupted and the label drops into the position shown in FIG. 3 on the
item 57 to be labeled. The arm 63 then is rotated back to its starting
position with the head 64 over the conveyor and, with the arm out of the
way, the upper platen 58 descends, sandwiching the label and fabric item
between the upper and lower platens and applying heat and pressure to the
label for a predetermined time period to thermally bond the label to the
fabric piece. The upper platen 58 is then retracted at the end of the
predetermined period, and the labeled item is withdrawn from the lower
platen and the next item is then positioned thereon to begin the next
cycle.
The entire bonding cycle lasts only a few seconds with the dwell time of
the upper platen 58 against the lower platen 56 typically lasting only
about one second. The temperatures of the upper and lower platens are
independently adjustable and it is desirable to maintain the lower platen
at a slightly higher temperature than the upper platen since the adhesive
layer will flow towards the higher temperature surface. The correct
temperature balance for a given fabric item to be labeled must be found
through trial and error since different fabrics will transfer heat at
different rates.
To prevent the label item from adhering to the upper platen when the upper
platen is raised, a pair of spaced pins 67 extending downwardly from
bracket 68 are disposed at each side of the upper platen. The bracket 68
and pins 67 are supported on post 69 which is selectively vertically
movable independently of the upper platen movement by means not shown.
When the upper platen descends and during the bonding interval, the lower
ends of the pins are at the same level as the upper platen lower surface.
When the upper platen ascends at the end of the bonding interval, however,
the upward travel of the pins is delayed momentarily and the pins thus
serve to disengage the labeled items from the upper platen should it
happen to adhere thereto.
The label film is composed of two discrete layers, which are adhered to
each other, one layer being specifically selected because of its ability
to bear imprinting, substantially without distortion, during the
processing within the system of the invention, and the other layer being
specifically selected because of its superior performance as an adhesive
in the fusion bonding process according to the invention. Both layers must
be able to withstand repeated exposure to laundering processes, detergent
and other substances used during home or commercial laundering, and, as
well, to withstand repeated exposure to dry cleaning. Both layers are
composed of elastomers which are thermoplastic, compatible with each other
and with the garment piece to which they are to be attached, soft,
pliable, exhibit good low temperature flexibility and have relatively high
abrasion resistance. By "soft" is meant soft to the touch, not sharp or
jagged. If a label is placed on a garment in a position in which the label
comes in contact with the skin of the wearer, such as inside the collar of
a shirt, a "soft" label is one which does not feel uncomfortable to the
wearer, one which does not tend to prick the neck of the wearer, or cause
the wearer discomfort. "Pliable" means that the label is supple, that is,
it conforms readily and easily to the folds or curved configurations to
which a garment is subjected by its wearer, both during use and when not
in use. "Low temperature flexibility" means that the label maintains its
position on the garment and continues to perform the intended function of
a label, even if the wearer of the garment is exposed to severe, even
extreme, cold, such as, minus 20.degree. F. or minus 30.degree. F.
The essential characteristics of the materials of the layers, according to
the invention, are as follows.
For the under layer, or adhesive layer, the essential characteristics are
washability, softness, dry cleanability, low temperature flexibility, good
adhesion to fabrics, and low melt point. For the upper layer, or the layer
to be imprinted, the essential characteristics are abrasion resistance,
dry cleanability, washability, high melt point, low temperature
flexibility, and good printability.
Both of the layers of thermoplastic resin are relatively thin, being in the
range of from about 0.001 to about 0.003 inches thick. The first layer of
relatively high melting point polyurethane is preferably about 0.002
inches thick, and the second, or adhesive, layer of relatively low melting
point polyurethane is preferably about 0.001 inches thick.
The label film layers are preferably polyurethane, but other suitable
synthetic resins such as polyester resin may be blended into, or used in
place of, one of the layers, particularly the upper or imprinted layer.
Adding polyester resin tends to increase the stiffness, or decrease the
softness, of the resulting label, which may be a desirable result for
certain applications.
Polyurethane films suitable for use with the invention can be produced as
either polyester or polyether based materials, with the polyester based
being preferred.
They are preferably produced in wide film form by extrusion, preferably
onto a release carrier strip, of paper or the like, which temporarily
supports the extrudate until it cools and becomes self-sustaining, either
in two passes or in one dual extrusion pass, as will be understood by
those skilled in the art of film extrusion.
For the layer to be used to receive the imprinting, it is preferred to use
relatively high melting point material, that is, material having a melting
point of from about 355.degree. to 365.degree. F. A suitable and preferred
material is a polyurethane film identified as Product U-840 by
Electro-Seal Corp., 55 Wanaque Avenue, Pompton Lakes, N.J. 07442. For the
adhesive layer it is preferred to use a low melting point material,
preferably a material having a melting point of from about 275.degree. to
about 290.degree. F. A suitable and preferred material is polyurethane
film identified as Product U-810, by the same Electro-Seal Corp., one of
the joint owners of the present application. Electro-Seal Corp. sells the
U-810 material and the U-840 material adhered to each other as Product
LT200. Physical properties of U-840 and U-810 are given in Table 1.
TABLE 1
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U-810 U-840
Under Layer (The
Upper Layer (The
Properties Adhesive Layer)
Layer to be Imprinted)
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Melt Point 275-290.degree. F.
355-365.degree. F.
Melt Index (ASTM Test
45-55 gm/10 mins.
5-15 gm/10 mins.
Method D-1238)
Color Clear with slight
Clear
amber tint
Shore Hardness A (ASTM
80A 95A
Test Method D-1240)
Wash and Dry Resistance
Excellent Excellent
Dry Cleaning Resistance
Excellent Excellent
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